0394 API 6A 19th Edition

Wood Group Pressure Control

Selection of Wellhead & Christmas Tree Products in compliance with API 6A 19th Edition

Mandatory February 1, 2005 08-0394-0

API specs are for CUSTOMERS to use •

API specifications are for the user: – For selecting materials suited to well conditions – For ordering equipment

•

API specifications impact the manufacturing process: (Criteria) – Temperature Class – Material Class (trim) – PSL (Product Specification Levels) • Recommended by API to the user for various service conditions – PR (Performance Requirements) • Levels of testing done to qualify product designs for monogram

•

API requires every monogrammed product to meet API specs for all 4 Criteria

08-0394-1

– With or without the API monogram – builds all new products to meet API requirements for • Temperature Class • Material Class • PSL • PR • Companies can be “API Licensed” for marketing reasons, but then rarely comply with API requirements – Licensed for 2 or 3 product types? – Don’t actually monogram parts? – Buy-out equipment of someone else’s design?

08-0394-2

API Material Classes (Trims) w/ limits for 17-4 SS (0.5 psia) and 410 SS (1.5 psia) stems & hanger mandrels

standard sour service ratings are “0,5” or “NL” H2S Partial Pressure

CO2 Partial Pressure

0 to < 7 psia 7 psia to 30 psia

> 30 psia to < 200 psia

200 psia and up Corrosion resistant alloys may be needed.

> 0.5 and < 1.5 psia ¹

> 1.5 psia ¹

0 to < 0.05 psia

0.05 to 0.5 psia

AA

EE-0,5 or DD-0,5

Non-Sour Non-Corrosive

Sour Non-Corrosive

Sour Non-Corrosive

Sour Non-Corrosive

BB

EE-0,5

EE-1,5 ²

EE-NL ³

Non-Sour

Sour

Sour

Sour

Slightly Corrosive

Slightly Corrosive

Slightly Corrosive

Slightly Corrosive

CC

FF-0,5

FF-1,5 ²

FF-NL ³

Non-Sour Moderately to Highly Corrosive

Sour Moderately to Highly Corrosive

Sour Moderately to Highly Corrosive

Sour Moderately to Highly Corrosive

CC or HH

FF-0,5 or HH-0,5

FF-1,5 or HH-1,5

FF-NL or HH-NL

Non-Sour

Sour

Sour

Sour

Highly Corrosive

Highly Corrosive

Highly Corrosive

Highly Corrosive

DD-1,5 or EE-1,5 ² DD-NL or EE-NL ³

Wood Group Pressure Control recommends that Corrosion Resistant Alloys be considered beginning at CO2 partial pressures of 200 psia. Consult with engineering for material selection. Additional factors should be considered.

¹ Material Class ZZ may be used when materials and trims previously used for sour service will not comply with current NACE MR0175/ISO15156 standards

² 17-4 stainless steel is not allowed for stems or tubing hangers above 0.5 psia H2 S. ³ 410 stainless steel is not allowed for stems or tubing hanger above 1.5 psia H2 S.

08-0394-3

Temperature Classes API 6A 19th Edition All products are built for a specific API temperature class Consider max flowing and min ambient temperature (mud temp?) • K -75 to 180 F • L -50 to 180 • N -50 to 140 • P -20 to 180 • R Room Temperature • S 0 to 140 • T 0 to 180 • U 0 to 250 • V 35 to 250 • X 0 to 350 (ref Annex G) • Y 0 to 650 (ref Annex G) “Choosing temperature ratings is the ultimate responsibility of the user” 08-0394-4

NACE: limits for materials in H2S service • 17-4 Stainless Steel Industry has historically used 17-4 SS for valve stems and tubing hangers for EE and FF sour service up to 3 or more psia H2S

• API 6A 19th Edition – –

17-4 SS is not allowed in sour service for hanger mandrels and stems above 0.5 psia H2S partial pressure Inconel has NO LIMIT for H2S partial Pressure • In many applications, 410 SS cannot be used as a substitute due to tensile strength requirements (re: hanger mandrels, stems)

• WGPC 19th Edition products for sour service: –

Hanger Mandrels and Products with stems • 17-4 SS up to .5 psia max H2S partial pressure • Inconel for No Limit to H2S partial pressure

08-0394-5

NACE: limits for materials in H2S service 316 Stainless Steel •

Industry has historically used 316 SS for fittings, needle valves and pressure gauges for EE and FF Sour service with no limit to H2S partial pressure

•

API 6A 19th Edition – 316 SS is not allowed in sour service when chlorides are present and temperatures are above 140 F – Effects grease & test fittings in all products in standard temperature ranges – Next NACE expected to change to max 200 F?

•

WGPC 19th edition products for sour service: – Low alloy fittings will be used in all alloy bodies – Nickel plated alloy or Inconel fittings are used in Stainless Steel bodies

08-0394-6

NACE effects API Material Classes •

19th Edition sour service Material Classes (Trims) must be labeled with the maximum allowable H2S partial pressure, depending on the materials of construction (may vary by manufacturer) WGPC 19th Edition Sour Service Material Classes (Trims) API 6A 17th Edition & earlier

API 6-A 19th Edition

DD

DD-0,5 (17-4 SS stem is allowed) or DD-NL (w/ low alloy NACE stem * inconel stem is allowed)

EE

EE-0,5 (w/ 17-4 SS stem) or EE-NL (w/ inconel stem)

FF

FF-0,5 (w/ 17-4 SS stem) or FF-NL (w/ inconel stem) 08-0394-7

19th Edition Changes NACE changes affect API materials •

0,5 suffix will appear on our products with internal parts – Valves – Tubing Hanger Mandrels* • API considers the tubing hanger mandrel an “internal part” of a wellhead assembly (as a stems are considered “internal parts” of valves)

•

NL suffix will appear on our products with no internal parts – – – –

Heads, Spools & Flanges Tubing Heads (lockscrews are not addressed by API 6A) Tubing Head Adapters, DSA’s (with or without packoffs) Tees, Crosses, Tree Caps

08-0394-8

API 6A 19th Edition •

Determine the required material class for sour service (EE or FF) – Find the exact H2S partial pressure • Your well(s) may be able to use 17-4 SS stems & tubing hangers

•

It takes a lot of H2S to go over .5 psia – @ 5,000# 100 PPM H2S = .5 psia – @ 10,000# 50 PPM H2S = .5 psia – @ 15,000# 33.3 PPM H2S = .5 psia

•

If WGPC quotations dept. doesn’t know the H2S partial pressure – WGPC will quote Valves & Hanger Mandrels (as applicable) rated by API for .5 psia maximum H2S partial pressure. A statement will appear on the quotation.

“Choosing material class and specific materials for specific conditions is the ultimate responsibility of the user” 08-0394-9

PSL (Product Specification Level) •

Quality Control & testing recommendations increase with severity of service – Working Pressure – H2S Concentration • More quality control = more measurements during manufacture & more extensive pressure testing

•

PSL 3G (new in 19th edition) – Replaces PSL 4 in API decision tree • PSL 3 QC for manufacturing + gas testing – PSL 4 is still available (if customer elects)

•

PSL decision tree criteria – Alternate questions can be used

08-0394-10

PSL (Product Specification Level) API “recommendations to users” • Many customers don’t follow these recommendations – Do customers assume this is taken care of because their supplier follows API requirements? • PSL’s are recommended by API to the user to specify his requirements to the manufacturer

– Are customers unaware of the details of API recommendations? • PSL recommendations apply to the 4 “Primary Parts” of a wellhead assembly – Tubing Head – Tubing Hanger – Tubing Head Adapter – Lower Master Valve » In some frac operations, the customer may consider the annulus valve on the side of the tubing head as a primary part as well.

08-0394-11

PSL (Product Specification Level) Decision Tree Alternate questions • High H2S Concentration? – Yes, if a leak will result in 70 PPM or more in air • If your well has less than 70 PPM H2S, the answer is NO

• Alternate: – Is the 100 PPM radius of exposure greater than 50 ft. from the wellhead? • Depending on flow rate, it is possible for wells with 70 PPM H2S or more to have a 100 PPM ROE less than 50 ft. from the wellhead – Radius of Exposure formulas are shown in API 6A, Annex A, A.4.5

08-0394-12

PSL (Product Specification Level) Decision Tree Alternate questions • Gas Well? • Alternate: customer may use Close Proximity and Radius of Exposure Analysis – Yes, if 100 PPM ROE > 50 ft. and includes any part of a public area except a public road – Yes, if 500 PPM ROE > 50 ft. and includes any part of a public area including a public road – Yes, if well is located: – In any environmentally sensitive area such as parks, wildlife preserve, city limits, etc. – Within 150 ft. of an open flame or fired equipment – Within 50 ft. of a public road (lease road excluded) – In or near inland navigable waters – In or near domestic water supplies – Within 350 ft. of any dwelling

08-0394-13

PR (Performance Requirement)

• Performance Requirement – Testing of product designs is required by API before a product is eligible to be monogrammed by the manufacturer • PR 1 (minimum required) • At room Temperature • Pressure and mechanical cycles – PR 2 (option of customer or manufacturer) • At room temperature • Additional pressure and mechanical cycles – Annex F adds temperature cycles (option of customer or manufacturer) • F PR 1 adds temperature max & min • F PR 2 most severe testing includes added # of cycles

08-0394-14

Quality Control at different PSL’s Bodies, End/Outlet Connections And Hub End Connections Requirement

Impact Testing of Raw Material

PSL 1

PSL 2

PSL 3/3G ¹

PSL 4 ¹

Temp K and L only

Temp K, L, N and P only

Temp K, L, N, P, R, S, T, U and V only

Same as PSL 3/3G

Test at or below bottom of temp range

Test at or below bottom of temp range

Test at or below bottom of temp range

Same as PSL 3/3G

Test all parts for all working pressures

Same as PSL 2 plus test locations on each end connection face

Same as PSL 3/3G

Examine all accessible wetted and sealing surfaces

Examine ALL accessible surfaces plus areas prepped for weld overlay

Same as PSL 3/3G

Not Required

Examine 100% volume as practical, both After heat treating and Before machining

Same as PSL 3/3G plus restricted acceptance criteria

5M & below - sample testing

Hardness Testing of Raw and Machined Parts

10M & above - test every part Sour service - test every part

Surface NDE ² of Machined Parts

Volumetric NDE ² of Raw Material

Not Required

Not Required

¹ PSL 3, 3G and 4 require serialization of each part ² Non-Destructive Examination

08-0394-15

Quality Control at different PSL’s Stems Requirement

Impact Testing of Raw Material

PSL 1

PSL 2

PSL 3/3G¹

PSL 4 ¹

Temp K, L, N and P only

Temp K, L, N, P, R, S, T, U and V only

Same as PSL 3/3G

Manufacturer's Material Specification Test at or below bottom of Test at or below bottom of temp range temp range

Same as PSL 3/3G

5M & below - sample testing Hardness Testing of Machined Parts

10M & above - test every part

Test all parts for all working pressures

Sour service - test every part

Surface NDE² of Machined Parts

Not Required

Examine all accessible wetted and sealing surfaces

Examine ALL accessible surfaces plus areas prepped for weld overlay

Same as PSL 3/3G

Volumetric NDE² of Raw Material

Not Required

Not Required

After heat treating and Before machining

Same as PSL 3/3G

¹ PSL 3, 3G and 4 require serialization of each part ² Non-Destructive Examination

08-0394-16

Quality Control at different PSL’s Valve Bore Sealing Mechanisms And Choke Trim³ Requirement

PSL 1

PSL 2

PSL 3/3G ¹

PSL 4¹

Tensile Testing of Raw Material

Not required

Not required

Manufacturer's Material Specification

Manufacturer's Material Specification

Hardness Testing of Machined Parts

Test all parts for sour service (DD, EE, FF, HH trims)

Surface NDE² of Machined Parts

Not Required

Test all parts for all working pressures

Examine all accessible wetted and sealing surfaces

Examine ALL accessible surfaces plus areas prepped for weld overlay

Same as PSL 3/3G

¹ PSL 3, 3G and 4 require serialization of each part ² Non-Destructive Examination ³ Choke trim: only surface NDE and serialization are required

08-0394-17

Quality Control at different PSL’s Valve Testing Requirement

PSL 1

PSL 2

PSL 3

PSL 3G

PSL 4

Hydrostatic Body Test

Two 3-minute holds

Two 3-minute holds

One 3-minute hold plus one 15minute hold

One 3-minute hold plus one 15minute hold

One 3-minute hold plus one 15-minute hold

Hydrostatic Seat Test

Two 3-minute holds

Two 3-minute holds

One 3-minute hold plus one 15minute hold

One 3-minute hold plus one 15minute hold

One 3-minute hold plus one 15-minute hold

Gas Body Test

Not required

Not required

Not required

One 15-minute hold @ WP

One 15-minute hold @ WP

Not required

One 15-minute hold @ WP plus one 15-minute hold @ 300 psi

One 1-hour hold @ WP fully open & close valve, one 1hour hold at 5 to 10% WP

Not required

Optional — One 15-minute hold @ WP

One 1-hour hold @ WP, disengage / reengage, one 1-hour hold @ 5 to10% WP

Gas Seat Test

Gas Back-Seat Test

Not required

Not required

Not required

Not required

08-0394-18

Quality Control at different PSL’s Casing and Tubing Hanger Mandrels/Bodies Requirement

PSL 1

PSL 2

PSL 3 ¹

PSL 4 ¹ ²

Impact Testing of Raw Material

Temp K & L only

Test every part

Same as PSL 2

Same as PSL 2

Hardness Testing after all heat treatment and machining

Test every part

Same as PSL 1

Same as PSL 2 plus additional test locations

Same as PSL 2 plus additional test locations

Not Required

Examine all accessible wetted and sealing surfaces

Examine ALL accessible surfaces plus areas prepped for weld overlay

Same as PSL 3

Not Required

Examine 100% volume as practical, both After heat treating and Before machining

Same as PSL 3 plus restricted acceptance criteria

Surface NDE ³ of Machined Parts

Volumetric NDE³ of Raw Material

Not Required

³ Non-Destructive Examination

08-0394-19

Quality Control at different PSL’s

Testing Of Casing & Tubing Heads, Tubing Head Adapters, Chokes, Crossover Connectors, Adapter And Spacer Spools Requirement

PSL 1

PSL 2 ¹

PSL 3 ¹

PSL 3G ¹ ²

PSL 4 ¹

Hydrostatic Test ³

Two 3-minute holds

Two 3-minute holds

One 3-minute hold plus one 15minute hold

One 3-minute hold plus one 15minute hold

One 3-minute hold plus one 15-minute hold

Gas Test ³

Not required

Not required

Not required

One 15-minute hold @ WP

One 15-minute hold @ WP

¹ PSL 2 and above: Serialization of assemblies is required. ² PSL3G assemblies are built with PSL3 components. ³ Separate tests are required above & below crossover seal.

08-0394-20